5.7L Hemi Cars - Vortech Superchargers

Transcription

5.7L
DOD
GE/C
Hem
HRY
SLER
i Ca
Gen
.2S
up
Inst
alla erchar
tion
ger
Sys
I
50 S
nstr
200
tem
tate
9-20
u
Smo
10 M
c
t
ions
g Le
ode
l Ye
gal
ars
per
C
ARB
EO#
rs
D-21
3-31
®
ENGINEERING, INC.
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com
i
P/N: 4CL020-015 v1.0, 12/02/2014
©2014 Vortech Engineering, Inc
All Rights Reserved, Intl. Copr. Secured
FOREWORD
T
his manual provides information on the installation, maintenance and service of the
Vortech supercharger kit expressly designed for this vehicle. All information, illustrations and specifications contained herein are based on the latest product information
available at the time of this publication. Changes to the manual may be made at any time
without notice. Contact Vortech Engineering for any additional information regarding this kit
and any of these modifications at (805) 247-0226 7:00am - 3:30pm PST.
Take note of the following before proceeding:
1. Proper installation of this supercharger kit requires general
automotive mechanic knowledge and experience. Please browse
through each step of this instruction manual prior to beginning the
installation to determine if you should refer the job to a professional installer/technician. Please contact your dealer or Vortech Engineering for possible installers in your area.
2. This product was designed for use on stock (un-modified, OEM) vehicles. The
PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If
the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no
boost) until the problem is resolved.
5. Vortech is not responsible for any clutch, transmission, drive-line or engine damage.
STOP
Exclusions from Vortech warranty coverage considerations include, but not
limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Vortech components with other modifications such as, but not limited to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.
© 2014 VORTECH ENGINEERING, INC.
All rights reserved. No part of this publication may be reproduced, transmitted, transcribed,
or translated into another language in any form, by any means without written permission
of Vortech Engineering, Inc.
P/N: 4CL020-015 v1.0, 12/02/2014
©2014 Vortech Engineering, Inc.
ii
Table Of Contents
FOREWORD...................................................................................................................................... ii
TABLE OF CONTENTS...................................................................................................................... iii
IMPORTANT NOTES......................................................................................................................... iv
TOOL & SUPPLY REQUIREMENTS.................................................................................................. vi
PARTS LISTS..................................................................................................................................... vii
1.
PREPARATION AND REMOVAL . ........................................................................................ 1
2.
FRONT FASCIA REMOVAL ................................................................................................. 2
3.
HARMONIC DAMPER DOWEL PIN INSTALLATION .......................................................... 3
4.
FUEL INJECTOR REPLACEMENT . .................................................................................... 4
5.
SUPERCHARGER MOUNTING PLATE INSTALLATION .................................................... 5
6.
SUPERCHARGER INSTALLATION .................................................................................... 8
7.
AIR INLET INSTALLATION .................................................................................................. 9
8. CHARGE AIR COOLER / DISCHARGE ASSEMBLY INSTALLATION . ............................... 11
9. RESERVOIR AND WATER PUMP ASSEMBLY AND INSTALLATION . ............................... 14
10. CHARGE AIR COOLER RADIATOR INSTALLATION . ........................................................ 15
11. FUEL PUMP VOLTAGE BOOSTER INSTALLATION ........................................................... 17
12. REFLASH COMPUTER........................................................................................................ 21
13. FINAL ASSEMBLY AND CHECKING.................................................................................... 22
iii
P/N: 4CL020-015 v1.0, 12/02/2014
OFF-HIGHWAY USE
When driving vehicle on non-public roads (off-road applications such as racing/high
RPM) Vortech strongly recommends reducing the factory spark plug gap down to
.032”.
COPYRIGHT NOTICE
This product is protected by state common law, copyright and/or patent. All legal rights
therein are reserved. The design, layout, dimensions, geometry and engineering
features shown in this product are the exclusive property of Vortech Engineering,
INC.. This product may not be copied or duplicated in whole or part, abstractly or
fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other
information be incorporated into any product or apparatus without prior written
consent of Vortech Engineering, Inc.
P/N: 4CL020-015 v1.0, 12/02/2014
iv
ATTENTION
BEFORE STARTING INSTALLATION,
PLEASE NOTE THE FOLLOWING:
• Double-click on the DS Downloader installer
Your vehicle’s ECM may need to be updated.
This can be determined by locating the supplied
Diablosport programmer and plugging it into the
vehicle’s OBD2 port.
on the desktop to start the installation process.
Follow the prompts to install.
• Once the installer has completed, locate the
new icon that the installer has placed on your
desktop. (See Fig)
Once the programmer is powered up and is at the
main menu screen, there will be four options to
choose from:
• Tune Vehicle
• Scan Tool
• Settings
• With the programmer powered up and con-
Select “Tune Vehicle “and follow the screen for
instructions.
nected to your computer, double-click on the
DSDownloader icon. You should see an option
If you are prompted to update the vehicle’s calibrato download calibration update.
tion, disconnect the Diablosport programmer and
• Select the update and allow the program to
follow these steps:
connect to Diablosport’s website. This may
take a few minutes.
Tools required: Diablosport U7778 Interface Kit.
• Once the programmer has updated, disconnect it from the power source and the comIn the event you are unable to purchase or
puter.
locate a U7778 Interface Kit, this process can be • Plug the programmer into the vehicles OBD2
accomplished by using the vehicle for the power
port and follow the main menu screen (as
source (by plugging the programmer into the vedescribed in section 10).
hicles OBD2 port) and by purchasing a USB to
serial cable (RS232) (Note: if your computer has
a serial cable outlet plug then just a serial cable
will be needed).
If you are unable to use the vehicle as the power
source, a power supply will be required.
The requirement for the power supply: Input
120 VAC 60Hz 30W output 12 VDC 1000
Ma, with a 5.5 x 2.5 mm tip, positive center.
With the programmer powered up and connected,
and the main menu screen being displayed:
• Type the following into your web browser:
vortechsuperchargers.com/dsinstaller
• Save the installer to your desktop. It should
place an installer icon on your desktop.
v
P/N: 4CL020-015 v1.0, 12/02/2014
Dodge/Chrysler Hemi Cars
Installation Instructions
Congratulations on selecting the best performing and best backed automotive
supercharger available today... the VORTECH® Supercharger!
Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owner’s Manual which includes the Automotive Limited Warranties Program
and the Warranty Registration form.
Vortech supercharger systems are performance improving devices. In most cases, increases in torque of
30‑35% and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering.
This product is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged
engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech
Engineering is not responsible for engine damage.
Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in
procedures are followed.
For best performance and continued durability, please take note of the following key
points:
1.
2.
3.
4.
Use only premium grade fuel 91 octane or higher (R+M/2).
The engine must have stock compression ratio.
If the engine has been modified in any way, check with Vortech prior to using this product.
Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem
is resolved.
5. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with
original heat range plugs as specified by the manufacturer and reset timing to factory specifications
(follow the procedures indicated within the factory repair manual and/or as indicated on the factory
underhood emissions tag). Do not use platinum spark plugs unless they are original equipment.
Change spark plugs every at least 15,000 miles and spark plug wires at least every 50,000 miles.
TOOL & SUPPLY REQUIREMENTS:
• Factory Repair Manual
• 3/8” Socket and Drive Set: SAE & Metric
• 1/2” Socket and Drive Set: SAE & Metric
• Adjustable Wrench • Open End Wrenches: 3/8”, 7/16”, 1/2”, 9/16”
• Flat #2 Screwdriver
• Phillips #2 Screwdriver
• Drill Motor
• 1/8”, 3/16”, 1/4”, 27/64” Drill Bits
• 3/16” Allen Wrench
• Wire Strippers and Crimpers
• Utility Knife
If your vehicle has in excess of 15,000 miles since its
last spark plug change, then you will also need:
• Spark Plug Socket
• NEW Spark Plugs
P/N: 4CL020-015 v1.0, 12/02/2014
vi
®
EE
GIN
EN
C.
, IN
G
RIN
2009-2010 5.7L Manual Challenger
Supercharger Kit
Part No. 4CL218-044L
®
PARTS LIST
ENGINEERING, INC.
IMPORTANT:Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately.
PART NO.
DESCRIPTION
QTY
008110small silver die cut decal 2
008130
LICENSE PLATE FRAME, VORTECH 1
008341
VORTECH CHARGE COOLER DECAL 1
008447
1 YR S/C STRT INFO PKG ASY VOR 1
009035
S/C LUBE, BOTTLED, VORT 3-PACK 1
2A046-106 BELT PREMIUM 104.5”, GATES
1
2F329-134 V3 S/C ASY, 2011 6.4l hemi cha 1
4CL010-160 BRKT, FLDYNE CHLLNGR DRVR 1
4CL010-170 BRKT, FLDYNE CHLLNGR PASS
1
4CL020-015 INSTR MAN, 09-10 5.7 HEMI car 1
4CL110-032 FUEL SYSTEM ASSY, 5.7L HEMI 1
4CL010-030 MAP SENSOR BLOCK, 07 CHARGER 1
4CL014-010
THERMOSTAT, 180º HEMI CAR
1
4CL145-010 ASSY, FUEL LINE, 2009 5.7L HEM
1
5A002-017
MAP SENSOR, 07 CHARGER SC
1
5A002-024 CONNECTR, MAP SNSR, 09 5.7L HE
1
5A002-025 SENSOR, IAT, 2005-08 DODGE HEM
1
7A250-074
1/4-20 X .75 HHCS PLTD
1
7C010-052
10-24 X 1/2 BUTTN HEAD CRWW
2
7F250-021
1/4-20 NYLOCK NUT ZINC PLATED
1
7J250-001
1/4 WASHER, SAE, PLTD
2
7P062-187
1/16NPT X 3/16 HOSE BARB
1
7P250-045
1/4 MALE NPT X 3/8 MALE BARB
2
7P375-113
PCV VALVE, VIPER, 3/8”-1/2” BA
1
7P500-003
1/2”-3/8” REDUCER BARB UNION
1
7R001-006 #6 STNLS HOSE CLAMP, NARROW
2
7R004-002
STEPLESS CLAMP, 17.0-70
2
7R004-687 STEPLESS CLAMP,13/16” ONE EAR
4
7U030-053
3/8 X 90º MOLDED RUBBER HOSE
1
8F060-008
FUEL INJECTOR, HEMI CHARGER
8
4CL110-054 ASSY, S/C MTG BRKT, 09 5.7L M6 1
008725
CAP, TAMPER PROOF, VORT S/C
2
2A017-016
PILOT, 6203/5 BRG, 3/8 SCREW
1
2A017-093
SPACER, S/C PULLEY, .093”
1
2A017-105-222B SPCR, BLK 1”OD X .328”ID X 2.225 5
2A017-156
SPCR, SM IDLER, DBL BRG JACK
1
2A017-462spacer, idler smooth 6 rib
1
2A017-750-09 spacer, .75 od x .363 l (p/s)
2
2A036-136 S/C PULLEY 3.60” 6 GROOVE W/FL
1
2A040-051
PLY RETAINER, TAMPER PRF CAP
2
2A040-061
RETAINER CUP, VORT S/C PLY
2
2A042-080
BELT, GATES 20MM, 80 TOOTH
1
2D070-159 LARGE BEARING,EXTENDED DRIVE
2
2D070-171
JACKSHAFT, C5, H900, 1INCH
1
4CL010-044B SC, MtG, PLT, BLACK ANODIZE
1
4CL010-221Bplate, cyl head 09-10 5.7l hemi
1
4CL010-230plt, sup, rear, 09 5.7l m6 hemi
1
4CL116-350 IDLER ASSY, 20MM GILMER, SRT8
1
4FD017-011
1
4FT017-080
SPCR, COOLER SUPPORT
1
4GR032-032 PULLEY,JACKSHAFT,C5,20MM,32T
1
4GR116-300 IDLER ASSY, 20MM GILMER, C5
1
4HS017-041 SPACER, LOWER S/C PLT S2000
2
4NZ030-041
BEARING HSG, 350Z
1
7A312-152
5/16-18 X 1.5 SHCS, ZN PLT
4
7A375-124
3/8-16 X 1-1/4 HHCS, G5, PLATE
4
7A375-225
3/8-16 X 2-1/4 HXHD G8
1
7B375-075
3/8-24 X 3/4” GR8 HXHD BOLT
1
7B375-150
3/8-24 X 1-1/2 GR8 HX
1
7C012-100 12MM X 100MM X 1.75 HXHD BOLT
1
7C080-025m8 x 1.25 x 25 hxhd
3
7C080-090
M8 X 1.25 X 90 HXHD CL10.9
3
PART NO.
DESCRIPTION
QTY
7C080-100
M8 X 1.25 X 100 HXHD Zn PLT
3
7C080-120
BOLT, 8MM X 120MM X 1.25 HXHD
1
7G010-175
12MM X 1.75 NUT
1
7J012-092
12MM WASHER, FLAT
1
7J312-000
5/16 FLAT WASHER-SAE
11
7J375-044
3/8 SAE WASHER, PLTD
4
7J500-002
1/2” WASHER, SPLIT LOCK
1
7U100-069
KEY, 3/16 SQUARE X .73 LONG
1
7U100-073
KEY, 3/16 SQUARE X 1.375 LONG
1
7U100-084
SNAP RING, EXT DRV HOUSING
1
7X100-027 WAVE WASHER, LARGE, V2 INPUT
1
4CL110-060 ASY,P/S,09 5.7L M6 hemi chal 1
7P375-075
3/4” HOSE BARB UNION, BRASS
1
7R004-007 STEPLESS CLAMP, 28.6 X 7MM WID
2
7R002-010
#10 SAE TYPE F SS HOSE CLAMP
1
7P500-078
1/2NPT X 3/4 HOSE FIT STRT
1
7P500-036
1/2 NPT, STREET, 45 DEG
1
4CL010-241
FITTING, P/S, 09 5.7L M6 HEMI
1
4CL110-110* ASSY, DAMPER PIN, HEMI
1
4CL112-030*
AIR INLET ASSY, HEMI
1
4CL112-074*AIR DISCH ASSY,HEMI CAR, G2
1
5A003-080tuner, ecu, diablosport in-tun1
5A102-031 ASSY, VOLT BOOST SRT8 HEMI G3 1
5A002-031
VOLT BOOSTER HEMI G3
1
5W001-021
1/2” SPLIT PLASTIC WIRE LOOM
2’
5W001-005
9’
5W001-032
20’
5W012-000
12GA. RED STRANDED WIRE
4’
5W012-010
12GA. BLACK STRANDED WIRE
4’
5W012-080 12GA. ORANGE STRANDED WIRE
8’
5W014-010
8’
7U030-024 1/8” NYLON INSTRUMENT TUBING
21’
7P156-082
5/32” TEE
1
7U030-109
7/64” VAC HOSE
.5’
7U100-044
4” NYLON TIE WRAPS
10
7U100-055
7.5” NYLON TIE WRAPS
10
5W001-014
FUSE HOLDER 10GA. WIRE
1
4CL010-260
MOUNTING PLATE FPB
1
7C010-050
10-24 X 1/2” SCREWS
4
7J010-001
#10 FLAT WASHER
4
7F010-024
10-24 NYLOCK NUT
4
7A250-074
1/4-20 X 3/4” HEX HEAD BOLT
2
7J250-001
1/4” WASHER
4
7F250-022
1/4-20 NYLOCK NUTS
2
5W001-007
3/16 HEAT SHRINK
.75’
5W001-038
1/4 HEAT SHRINK
.75’
5W001-04310-12GA. 1/4” YELLOW RING TERMINAL 2
5W001-041 10-12GA. YELLOW SLIDE CONN MALE 2
5W001-04010-12GA. YELLOW SLIDE CONN FEMALE 2
5W001-019
10-12GA. YELLOW BUTT CONN 1
5W001-009 14-16GA. BLUE SLIDE CONN MALE
1
5W001-010 14-16GA. BLUE SLIDE CONN FEMALE 1
5W001-013
14-16GA. BLUE BUTT CONN 2
8N006-020WATER COOLR, FLDYN DUAL PASS 1
8N105-220*WATER TANK ASSY, 2011 6.4 HEMI 1
8N107-190*WATER PUMP MTG ASSY, 07 CHGR 1
8N201-394 WELDED,CORE ASSEMBLY,HEMI 1
*see page viii for individual components in assembly
vii
P/N: 4CL020-015 v1.0, 12/02/2014
Supercharger Kit (cont’d)
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
008110small silver die cut decal
008130
LICENSE PLATE FRAME, VORTECH
008341
VORTECH CHARGE COOLER DECAL
008447
1 YR S/C STRT INFO PKG ASY VOR
009035
S/C LUBE, BOTTLED, VORT 3-PACK
2F329-134 V3 S/C ASY, 2011 6.4l hemi cha
4CL010-160 BRKT, FLDYNE CHLLNGR DRVR
4CL010-251 BRKT, CAC SUPRT, HEMI CHALL
4CL020-015 INSTR MAN, 09-10 5.7 HEMI car
QTY
2
1
1
1
1
1
1
1
1
1
1
4CL110-032*FUEL SYSTEM ASSY, 5.7L HEMI 1
4CL110-054* ASSY, S/C MTG BRKT, 09 5.7L M6 1
4CL110-060*ASY,P/S,09 5.7L M6 hemi chal 1
4CL110-110
ASSY, DAMPER PIN, HEMI
1
4GR010-110
GUIDE, DWL PIN INST
1
7C014-095
M14-1.5 X 95MM SHCS
1
7U250-019
DOWEL PIN, 1/4X1/2 +.001”
1
7U250-026 DRILL BUSHING, 1/4 ID, 3/8 OD, 1/2L
1
4CL112-074 AIR DISCH ASSY,HEMI CAR, G2
1
4CL010-310
DISCHARGE DUCT SUPPORT
1
4CL012-074
DISCHARGE DUCT “A” COATED
1
4CL012-084
DISCHARGE DUCT “B” COATED
1
4CL012-104 DISCH TUBE “C”, 2009 5.7L HEMI
1
7PS275-100
SLEEVE, BLACK, 2.750D X 1.00
1
7PS275-300
4
7PS350-279
ELBOW, SIL 3.5X2.75 90º, BLK
1
7R002-016
2
7R002-044
#44 SAE TYPE F SS HOSE CLAMP 10
7R002-056
1
7U030-046
5/32” VACUUM LINE
5’
7U034-016
1” GS HEATER HOSE
.25
8D001-004 COMPRESS BYPASS VALVE, G2
1
8H040-075 FILTER, 1” BYPASS VALVE
1
4CL112-030
1
4CL010-180
BRKT, CHALLENGER AIR INLET
1
4CL012-030 DUCT, INLET 08 HEMI CHALLENGER 1
7A250-039
1/4-20 X 3/8” SHCS ZINC PLTD
2
7J250-001
2
7R002-056
1
7R002-080
1
7S500-351
INLET SLEEVE, HEMI, 5 X 3.5
1
8H040-235
AIR FILTER, 4” FLG X 7.0L
1
7P500-009
1/2”x90 hose barb union
1
7U030-036
1/2” Oil Drain Hose
4’
8H040-300air filter 300c
1
7U032-020
3/8 p/s hose
32”
5A003-080tuner, ecu, diablosport in-tun 1
5A102-031*ASSY, VOLT BOOST SRT8 HEMI G3
8N006-020WATER COOLR, FLDYN DUAL PASS
8N105-220WATER TANK ASSY, 2011 6.4 HEMI
4CL010-190
BRKT, CAC TANK, HEMI
7A250-050
1/4-20 X .50 SHCS GR8 ZINC PLT
7A250-051
1/4-20 X .50 HHCS GR5 ZINC PLT
7A250-101
1/4-20 X 1 HHCS ZINC PLTD
7E010-075
#12 X 3/4” SHT METL SCRW HEX 7J250-001
7P375-075
7P500-026
1/2NPT X 3/4 BARB 90º BRASS P/N: 4CL020-015 v1.0, 12/02/2014
PART NO.
DESCRIPTION
7P500-075
1/2NPT X 3/4 HOSE FIT STRT NIC
7R007-001
NYLON RATCHET CLAMP 1-1/8”
7U038-000
3/4” HEATER HOSE 7U038-012
HOSE, 3/4 DIA 90º, 4 X 12 LEGS
7U038-150 HOSE, 3/4 D X 150º MOLDED HOSE
7U100-044
TIE WRAP, 4” NYLON
7U100-055
TIE WRAP, 7.5” NYLON
8N055-030
TANK, WATER TRIANGLE SHAPE
8N055-050
PLASTIC CAP, SURGE TANK
7P500-034
1/2NPT X 3/4 BARB 90º, NICKEl
7P500-035
FITTING, 1/2 NPT X 3/4 BARB X
4CL010-290 BRKT, SURGE TANK, FILL ’11 6.4
8N056-060
SURGE TANK, PLASTIC
7F375-016
3/8-16 HX NUT
2A017-881-01 SPACER, .875 OD X .532 LONG
7J375-044
7A375-350
3/8-16 X 3.5” HX HD GR5
4CL010-280
MTG BRKT, CAC, 2011 6.4 HEMI
4CL010-160 BRKT, FLDYNE CHALLENGER DR
4CL010-170 BRKT, FLDYNE CHALLENGER PA
8N107-190 WATER PUMP MTG ASSY, 07 CHGR
5W001-011
16-14 GA RING TERM .26” HOLE
5W001-013
14-16 GA BUTT CONN BLU INSUL
5W001-024
MINI ATC FUSE TAP
5W001-025
FEMALE SLIDE,INSULATED,MINI
5W001-054
18 GA FUSE HOLDER
5W014-030
14GA STRD WIRE BLACK
7R003-027
ADEL CLAMP,1-11/16”
8F001-402
PUMP, WATER, PIERBURG
8N100-001
NYLON MOUNTING KIT
8N201-394 WELDED,CORE ASSEMBLY,HEMI
QTY
5
19
9’
5
1
10
10
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
5
1
1
1
1
*see page vii for individual components in assembly
1
1
1
1
4
2
1
8
7
5
2
viii
Tuner Kit
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
008130
008341
008447
009035
QTY
2
1
1
1
1
1
1
1
1
1
PART NO.
DESCRIPTION
QTY
1
1
4CL112-030*
1
4CL110-054 ASSY, S/C MTG BRKT, 09 5.7L M6 1
008725
2
2A017-016
1
2A017-093
1
2A017-105-222B SPCR, BLK 1”OD X .328”ID X 2.225 5
2A017-156
1
2A017-462spacer, idler smooth 6 rib
1
2A017-750-09 spacer, .75 od x .363 l (p/s)
2
1
2A040-051
2
2A040-061
2
2A042-080
1
2
2D070-171
1
1
4CL010-221Bplate, cyl head 09-10 5.7l hemi
1
4CL010-230plt, sup, rear, 09 5.7l m6 hemi
1
1
4FD017-011
1
4FT017-080
1
1
1
2
4NZ030-041
BEARING HSG, 350Z
1
7A312-152
5/16-18 X 1.5 SHCS, ZN PLT
4
7A375-124
3/8-16 X 1-1/4 HHCS, G5, PLATE
4
7A375-225
3/8-16 X 2-1/4 HXHD G8
1
7B375-075
1
7B375-150
3/8-24 X 1-1/2 GR8 HX
1
1
7C080-025m8 x 1.25 x 25 hxhd
3
7C080-090
M8 X 1.25 X 90 HXHD CL10.9
3
7C080-100
3
7C080-120
1
7G010-175
12MM X 1.75 NUT
1
7J012-092
12MM WASHER, FLAT
1
7J312-000
11
7J375-044
4
7J500-002
1
7U100-069
1
7U100-073
1
7U100-084
1
1
4CL110-060 ASY,P/S,09 5.7L M6 hemi chal 1
7P375-075
1
7R004-007 STEPLESS CLAMP, 28.6 X 7MM WID
2
7R002-010
1
7P500-078
1/2NPT X 3/4 HOSE FIT STRT
1
7P500-036
1/2 NPT, STREET, 45 DEG
1
4CL010-241
FITTING, P/S, 09 5.7L M6 HEMI
1
*see page x for individual components in assembly
ix
P/N: 4CL020-015 v1.0, 12/02/2014
Tuner Kit (cont’d)
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
008130
008341
008447
009035
QTY
2
1
1
1
1
1
1
1
1
1
4CL110-054*ASSY, S/C MTG BRKT, 09 5.7L M6 1
4CL110-060*ASY,P/S,09 5.7L M6 hemi chal 1
4CL110-110
1
4GR010-110
GUIDE, DWL PIN INST
1
7C014-095
M14-1.5 X 95MM SHCS
1
7U250-019
DOWEL PIN, 1/4X1/2 +.001”
1
1
1
4CL010-310
1
4CL012-074
1
4CL012-084
1
1
7PS275-100
1
7PS275-300
4
7PS350-279
1
7R002-016
2
7R002-044
7R002-056
1
7U030-046
5/32” VACUUM LINE
5’
7U034-016
1” GS HEATER HOSE
.25
1
1
4CL112-030
1
4CL010-180
1
7A250-039
2
7J250-001
2
7R002-056
1
7R002-080
1
7S500-351
1
8H040-235
1
7P500-009
1
7U030-036
4’
1
7U032-020
3/8 p/s hose
32”
8N105-220WATER TANK ASSY, 2011 6.4 HEMI 1
4CL010-190
1
7A250-050
4
7A250-051
2
7A250-101
1
7E010-075
#12 X 3/4” SHT METL SCRW HEX 8
7J250-001
7
7P375-075
5
7P500-026
1/2NPT X 3/4 BARB 90º BRASS 2
7P500-075
5
7R007-001
19
7U038-000
3/4” HEATER HOSE 9’
7U038-012
5
P/N: 4CL020-015 v1.0, 12/02/2014
PART NO.
DESCRIPTION
QTY
1
7U100-044
10
7U100-055
10
8N055-030
1
8N055-050
1
7P500-034
2
7P500-035
2
1
8N056-060
SURGE TANK, PLASTIC
1
7F375-016
3/8-16 HX NUT
1
2A017-881-01 SPACER, .875 OD X .532 LONG
1
7J375-044
2
7A375-350
3/8-16 X 3.5” HX HD GR5
1
4CL010-280
1
1
1
8N107-190WATER PUMP MTG ASSY, 07 CHGR 1
5W001-011
1
5W001-013
2
5W001-024
MINI ATC FUSE TAP
1
5W001-025
1
5W001-054
18 GA FUSE HOLDER
1
5W014-030
5
7R003-027
1
8F001-402
1
8N100-001
NYLON MOUNTING KIT
1
*see page ix for individual components in assembly
x
2009-2010 5.7L Automatic Challenger
Supercharger Kit
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
008130
008341
008447
009035
4CL110-032 FUEL SYSTEM ASSY, 5.7L HEMI
4CL010-030 MAP SENSOR BLOCK, 07 CHARGER
4CL014-010
THERMOSTAT, 180º HEMI CAR
4CL145-010 ASSY, FUEL LINE, 2009 5.7L HEM
5A002-017
MAP SENSOR, 07 CHARGER SC
5A002-024 CONNECTR, MAP SNSR, 09 5.7L HE
5A002-025 SENSOR, IAT, 2005-08 DODGE HEM
7A250-074
1/4-20 X .75 HHCS PLTD
7C010-052
10-24 X 1/2 BUTTN HEAD CRWW
7F250-021
1/4-20 NYLOCK NUT ZINC PLATED
7J250-001
7P062-187
1/16NPT X 3/16 HOSE BARB
7P250-045
1/4 MALE NPT X 3/8 MALE BARB
7P375-113
PCV VALVE, VIPER, 3/8”-1/2” BA
7P500-003
1/2”-3/8” REDUCER BARB UNION
7R001-006 #6 STNLS HOSE CLAMP, NARROW
7R004-002
STEPLESS CLAMP, 17.0-70
7R004-687 STEPLESS CLAMP,13/16” ONE EAR
7U030-053
3/8 X 90º MOLDED RUBBER HOSE
8F060-008
FUEL INJECTOR, HEMI CHARGER
4CL110-074 ASSY, S/C MTG BRKT,09-10 5.7L
008725
2A017-016
2A017-093
2A017-105-222B SPCR, BLK 1”OD X .328”ID X 2.225
2A017-462
SPACER,IDLER SMOOTH 6RIB
2A017-156
2A017-876-12 sPAcER, .875 OD X .475 LONG
2A040-051
2A040-061
2A042-080
2D070-171
4CL010-010
BRK, PWR STR MTG, 07 chrg
4cl010-020B PLATE, HEAD, mTG, BLK ANODIZE
4CL010-200brKT, 6.1L HEMI CAR cLR SPT
4CL010-050
BrKT, 5.7L HEMI CAR cLR SPT
4CL016-011
HUB, PWR STR PLLY, HEMI CAR
4CL016-021
PULLEY, pwr str, hemi car
4FD017-011
4FT017-080
4NZ030-041
BEARING HSG, 350Z
7A250-075
1/4-20 x .75 shcs pltd
7A312-152
5/16-18 X 1.5 SHCS, ZN PLT
7A375-124
3/8-16 X 1-1/4 HHCS, G5, PLATE
7A375-225
3/8-16 X 2-1/4 HXHD G8
QTY
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
1
1
2
2
4
1
8
1
2
1
1
5
1
1
2
1
2
2
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
6
4
4
1
PART NO.
DESCRIPTION
QTY
7B375-075
1
7B375-150
3/8-24 X 1-1/2 GR8 HX
1
1
7C080-066m8 x 1.25 x 65 hxhd cl10.9
1
7C080-090
M8 X 1.25 X 90 HXHD CL10.9
3
7C080-100
3
7C080-120
1
7G010-175
12MM X 1.75 NUT
1
7J012-092
12MM WASHER, FLAT
1
7J312-000
11
7J375-044
4
7J500-002
1
7k250-001
1/4” an washer
6
7U100-069
1
7U100-073
1
7U100-084
1
1
1
1
4CL112-030* AIR INLET ASSY, HEMI CHAL
1
5A102-031 ASSY, VOLT BOOST SRT8 HEMI G3 1
5A002-031
VOLT BOOSTER HEMI G3
1
5W001-021
2’
5W001-005
9’
5W001-032
20’
5W012-000
4’
5W012-010
12GA. BLACK STRANDED WIRE
4’
5W012-080 12GA. ORANGE STRANDED WIRE
8’
5W014-010
8’
7U030-024 1/8” NYLON INSTRUMENT TUBING
21’
7P156-082
5/32” TEE
1
7U030-109
7/64” VAC HOSE
.5’
7U100-044
4” NYLON TIE WRAPS
10
7U100-055
7.5” NYLON TIE WRAPS
10
5W001-014
FUSE HOLDER 10GA. WIRE
1
4CL010-260
MOUNTING PLATE FPB
1
7C010-050
10-24 X 1/2” SCREWS
4
7J010-001
#10 FLAT WASHER
4
7F010-024
10-24 NYLOCK NUT
4
7A250-074
1/4-20 X 3/4” HEX HEAD BOLT
2
7J250-001
1/4” WASHER
4
7F250-022
1/4-20 NYLOCK NUTS
2
5W001-007
3/16 HEAT SHRINK
.75’
5W001-038
1/4 HEAT SHRINK
.75’
5W001-04310-12GA. 1/4” YELLOW RING TERMINAL 2
5W001-041 10-12GA. YELLOW SLIDE CONN MALE 2
5W001-04010-12GA. YELLOW SLIDE CONN FEMALE 2
5W001-019
10-12GA. YELLOW BUTT CONN 1
5W001-009 14-16GA. BLUE SLIDE CONN MALE
1
5W001-010 14-16GA. BLUE SLIDE CONN FEMALE 1
5W001-013
14-16GA. BLUE BUTT CONN 2
*see page xII for individual components in assembly
xi
P/N: 4CL020-015 v1.0, 12/02/2014
Supercharger Kit (cont’d)
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
QTY
008130
008341
008447
009035
1
1
4CL110-032*FUEL SYSTEM ASSY, 5.7L HEMI
1
4CL110-074*ASSY, S/C MTG BRKT,09-10 5.7L 1
4CL110-110
1
4GR010-110
GUIDE, DWL PIN INST
1
7C014-095
M14-1.5 X 95MM SHCS
1
7U250-019
DOWEL PIN, 1/4X1/2 +.001”
1
1
1
4CL010-310
1
4CL012-074
1
4CL012-084
1
1
7PS275-100
1
7PS275-300
4
7PS350-279
1
7R002-016
2
7R002-044
7R002-056
1
7U030-046
5/32” VACUUM LINE
5’
7U034-016
1” GS HEATER HOSE
.25
1
1
4CL112-030 AIR INLET ASSY, HEMI CHAL
1
4CL010-180
1
7A250-039
2
7J250-001
2
7R002-056
1
7R002-080
1
7S500-351
1
8H040-235
1
7P500-009
1
7U030-036
4’
1
7U032-020
3/8 p/s hose
32”
PART NO.
DESCRIPTION
QTY
7U038-012
5
1
7U100-044
10
7U100-055
10
8N055-030
1
8N055-050
1
7P500-034
2
7P500-035
2
1
8N056-060
SURGE TANK, PLASTIC
1
7F375-016
3/8-16 HX NUT
1
2A017-881-01 SPACER, .875 OD X .532 LONG
1
7J375-044
2
7A375-350
3/8-16 X 3.5” HX HD GR5
1
4CL010-280
1
1
1
8N107-190WATER PUMP MTG ASSY, 07 CHGR 1
5W001-011
1
5W001-013
2
5W001-024
MINI ATC FUSE TAP
1
5W001-025
1
5W001-054
18 GA FUSE HOLDER
1
5W014-030
5
7R003-027
1
8F001-402
1
8N100-001
NYLON MOUNTING KIT
1
*see page xi for individual components in assembly
5A102-031*ASSY, VOLT BOOST SRT8 HEMI G3 1
4CL010-190
1
7A250-050
4
7A250-051
2
7A250-101
1
7E010-075
7J250-001
7
7P375-075
5
7P500-026
7P500-075
5
7R007-001
19
7U038-000
P/N: 4CL020-015 v1.0, 12/02/2014
xii
Tuner Kit
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
QTY
008130
008341
008447
009035
1
1
4CL110-074 ASSY, S/C MTG BRKT,09-10 5.7L
008725
2A017-016
2A017-093
2A017-105-222B SPCR, BLK 1”OD X .328”ID X 2.225
2A017-462
SPACER,IDLER SMOOTH 6RIB
2A017-156
2A017-876-12 sPAcER, .875 OD X .475 LONG
2A040-051
2A040-061
2A042-080
2D070-171
4CL010-010
BRK, PWR STR MTG, 07 chrg
4cl010-020B PLATE, HEAD, mTG, BLK ANODIZE
4CL010-200brKT, 6.1L HEMI CAR cLR SPT
4CL010-050
BrKT, 5.7L HEMI CAR cLR SPT
4CL016-011
HUB, PWR STR PLLY, HEMI CAR
4CL016-021
PULLEY, pwr str, hemi car
4FD017-011
4FT017-080
4NZ030-041
BEARING HSG, 350Z
7A250-075
1/4-20 x .75 shcs pltd
7A312-152
5/16-18 X 1.5 SHCS, ZN PLT
7A375-124
3/8-16 X 1-1/4 HHCS, G5, PLATE
7A375-225
3/8-16 X 2-1/4 HXHD G8
7B375-075
7B375-150
3/8-24 X 1-1/2 GR8 HX
7C080-066m8 x 1.25 x 65 hxhd cl10.9
7C080-090
M8 X 1.25 X 90 HXHD CL10.9
7C080-100
7C080-120
7G010-175
12MM X 1.75 NUT
7J012-092
12MM WASHER, FLAT
7J312-000
7J375-044
7J500-002
7k250-001
1/4” an washer
7U100-069
7U100-073
7U100-084
PART NO.
DESCRIPTION
QTY
1
1
4CL112-030* AIR INLET ASSY, HEMI CHAL
1
*see page xiv for individual components in assembly
1
1
2
1
1
5
1
1
2
1
2
2
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
6
4
4
1
1
1
1
1
3
3
1
1
1
11
4
1
6
1
1
1
1
xiii
P/N: 4CL020-015 v1.0, 12/02/2014
Tuner Kit (cont’d)
®
PARTS LIST
ENGINEERING, INC.
PART NO.
DESCRIPTION
QTY
008130
008341
008447
009035
1
1
4CL110-074*ASSY, S/C MTG BRKT,09-10 5.7L
4CL110-110
4GR010-110
GUIDE, DWL PIN INST
7C014-095
M14-1.5 X 95MM SHCS
7U250-019
DOWEL PIN, 1/4X1/2 +.001”
4CL010-310
4CL012-074
4CL012-084
7PS275-100
7PS275-300
7PS350-279
7R002-016
7R002-044
#44 SAE TYPE F SS HOSE CLAMP 7R002-056
7U030-046
5/32” VACUUM LINE
7U034-016
1” GS HEATER HOSE
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
2
10
1
5’
.25
1
1
PART NO.
DESCRIPTION
QTY
8N055-030
1
8N055-050
1
7P500-034
2
7P500-035
2
1
8N056-060
SURGE TANK, PLASTIC
1
7F375-016
3/8-16 HX NUT
1
2A017-881-01 SPACER, .875 OD X .532 LONG
1
7J375-044
2
7A375-350
3/8-16 X 3.5” HX HD GR5
1
4CL010-280
1
1
1
5W001-011
1
5W001-013
2
5W001-024
MINI ATC FUSE TAP
1
5W001-025
1
5W001-054
18 GA FUSE HOLDER
1
5W014-030
5
7R003-027
1
8F001-402
1
8N100-001
NYLON MOUNTING KIT
1
*see page xiii for individual components in assembly
4CL112-030 AIR INLET ASSY, HEMI CHAL
1
4CL010-180
1
7A250-039
2
7J250-001
2
7R002-056
1
7R002-080
1
7S500-351
1
8H040-235
1
7P500-009
1
7U030-036
4’
1
7U032-020
3/8 p/s hose
32”
4CL010-190
1
7A250-050
4
7A250-051
2
7A250-101
1
7E010-075
7J250-001
7
7P375-075
5
7P500-026
7P500-075
5
7R007-001
19
7U038-000
7U038-012
5
1
7U100-044
10
7U100-055
10
P/N: 4CL020-015 v1.0, 12/02/2014
xiv
1.
PREPARATION AND REMOVAL
A. Disconnect negative cable at the battery.
B. Remove the plastic engine covers and set
aside.
C. Remove the valve cover breather hose from the
factory air inlet duct. Remove the air filter and all
ducting upstream of the throttle body.
D. Unplug the IAT (Inlet Air Temperature) sensor
connector and remove it from the air filter housing. Set it aside for later use.
E. Remove the accessory drive belt.
F. Unplug the fan electrical connector, then remove
fan shroud hardware. Pull up and remove the
electric radiator fan assembly from the vehicle
(cooling system may need to be drained and
upper radiator hose removed).
G. 2009-2010 Challenger A/T Only: Using an appropriate power steering pulley removal tool,
remove the power steering pump pulley from
the pump.
H. 2009-2010 Challenger A/T Only: Install the supplied power steering pulley hub onto the power
steering pump so that it is flush with the end of
the shaft. (See Fig. 1-a)
1
Fig. 1-a (A/T Only)
P/N: 4CL020-015 v1.0, 12/02/2014
2.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
FRONT FASCIA REMOVAL
Remove the plastic splash pan on the bottom of
the vehicle.
Remove the electrical plug for the fog lights
located on the passenger side of the vehicle.
Remove the plastic rivets securing the inner
fender liners (new rivets are supplied for re-installation).
Locate the two 10mm headed screws in the
front outer edge of the inner fender (one on
each side of the vehicle) (See Fig 2-a). Remove
the screws and set aside to be reinstalled in a
later step.
Locate and remove the four 10 mm nuts (Two
on each side of the vehicle) (See Fig. 2-b)
Remove the two covers from the top of the fascia (See Fig. 2-c)
Remove the six plastic retaining clips securing
the top of the fascia to the radiator core support.
Gently pull the corners of the fascia way from
the fenders. And remove the fascia.
Remove the plastic clips retaining the inner fascia support. And remove the inner fascia support. (See Fig. 2-d, 2-e)
Remove the three 8 mm headed screws from
the drivers side headlight.
Pull the headlight straightforward and remove.
Remove the two head light plugs. And set the
head light assembly aside.
Fig. 1-a
Fig. 2-a (Challenger Shown)
10MM STUDS
Fig. 2-b (Challenger Shown)
Fig. 2-c (Challenger Shown)
Fig. 2-e (Challenger Shown)
Fig. 2-d (Challenger Shown)
P/N: 4CL020-015 v1.0, 12/02/2014
2
3.
HARMONIC DAMPER DOWEL PIN INSTALLATION
NOTE:The purpose of this section is to provide access to the harmonic damper bolt area so that
the crankshaft can be pinned to the damper
to prevent the damper from spinning on the
crankshaft. The following steps will work on
all or most applications. If it is not possible
to get adequate clearance by performing the
following steps, follow the manufacturer’s
steps for removing the harmonic damper until
there is sufficient room to work in.
A. Remove the crankshaft damper bolt. (A factory tool may be used to keep the engine from
rotating or carefully use a pry tool to keep the
damper from rotating.)
B. Install the supplied drill guide with the raised
section piloting in the damper bore. Secure
in place by installing the supplied socket head
cap screw. Do not over-tighten the screw as it
may distort the drill guide (its purpose is just to
hold the guide in place while drilling). See Fig.
3-a.
Fig. 3-a
1” MINIMUM
C. Using a small drill motor (right angle pneumatic
works well), mark a 1/4” drill bit with electrical
tape or a drill stop so that the hole will be deep
enough for the supplied 1/2” long dowel pin.
See Fig. 3-b.
D. Drill hole in damper/crankshaft.
E. Remove the socket head cap screw.
F. Clean area of metal chips and install the supplied
dowel pin in the drilled hole making sure that it
does not protrude past the damper face.
Fig. 3-b
G. Install and tighten the crankshaft damper bolt
to 129 ft-lbs (176 Nm).
H. Re-install the radiator fans and verify that the
electrical connector is plugged in.
3
P/N: 4CL020-015 v1.0, 12/02/2014
4.
FUEL INJECTOR REPLACEMENT
A. Relieve the fuel system pressure
B. Disconnect the eight fuel injector plugs and
retaining clips from the injectors.
C. Remove the four screws that hold down the fuel
rail on the intake manifold. Lift up on the rails
evenly and remove all eight injectors.
D. Using a small amount of clean motor oil, lightly
lubricate the O-rings on both ends of the Vortech
supplied fuel injectors.
E. Install the new injectors into the fuel rails with
the terminals facing outward.
F. Carefully lower the fuel rail/injector assembly
down onto the intake manifold.
G. Check to see that each injector has been seated
properly into the intake manifold.
H. Tighten down the passenger side of the fuel rail
assembly with the original bolts and attach the
injector plugs to the injectors.
I. Use the supplied PCV valve, ½” to 3/8” hose
union and 3/8” 90º hose to splice into the factory crank case breather hose as shown in Fig.
4-a.
J. Tighten a stepless clamp on each hose connection.
K. Cut the brake booster line next to the brake booster and install the aluminum MAP sensor block
assembly. Install a clamp on each connection.
Unplug the connector from the factory MAP sensor on the back of the intake manifold and plug
it into the supplied MAP sensor. (See Fig. 4-b)
2009-2010 5.7L Challenger Only: Install
dummy plug into factory MAP sending unit to
keep it from rotating out. (See Fig. 4-c)
Fig. 4-a
Fig. 4-b
MAP SENSOR
Fig. 4-c
P/N: 4CL020-015 v1.0, 12/02/2014
4
5.
SUPERCHARGER MOUNTING PLATE INSTALLATION
A. Remove the three bolts securing the power steering pump to the head. 2009-2010 5.7L engines
with M/T require removal of the inlet fitting for
the power steering pump to be replaced with the
supplied fitting. Set aside the hose as it will be
used in a later step. Refer to Fig. 5-b, 5-c & 5-d
for final installation reference
B. Loosely attach the steel bracket to the back of
the primary mounting plate.
C. Attach the supercharger mounting plate to the
primary mounting plate using the supplied M8
x90mm bolts and spacers.
D. Without installing hardware, sandwich the
power steering pump between the steel
plate and the supercharger mounting plate.
At this point, tighten the two bolts attaching the
steel bracket to the primary mounting plate.
(Loosely installed in Steb B.)
SUPERCHARGER
MTG PLATE
PRIMARY MTG
PLATE
STEEL
BRACKET
Fig. 5-a
NOTE:This is difficult to accomplish with the
power steering lines connected. It may be
easier to completely remove the power
steering pump from the vehicle and install
onto the mounting bracket assembly out
of the vehicle.
NOTE: 2009-2010 5.7L Challenger M6 Only:
continue with steps E, F, G. All other systems reattach the power steering lines now
and skip to Section 6.
Fig. 5-b (2009-2010 5.7L Challenger M6)
Fig. 5-c (2009-2010 5.7L Challenger M6)
Fig. 5-d (2009-2010 5.7L Challenger M6)
5
P/N: 4CL020-015 v1.0, 12/02/2014
5.
SUPERCHARGER MOUNTING PLATE INSTALLATION
Steps E, F and G apply to 2009-2010 5.7L
Challenger M6 Only:
E. Remove power steering hose from pump to reservoir. Cut hose as depicted in Fig. 5-e Set aside
the two longer pieces of hose and discard the
two shorter pieces. Replace the small bend with
a ¾ hose union and attach the 2 pieces of hose
together.
F. Install the hose so that the end with the single
bend attaches to the pump. Do not install clamps.
Mark union for correct clocking. Remove the hose
from the car and install stepless clamps at union.
(See Fig. 5-f)
G. Install hose assembly back into car using the
factory clamp to secure the hose to the reservoir
and a supplied hose clamp to attach the hose to
the power steering pump. (See Fig. 5-g)
Fig. 5-e (2009-2010 5.7L
Charger/Challenger M6)
Fig. 5-f (2009-2010 5.7L
Fig. 5-g (2009-2010 5.7L
P/N: 4CL020-015 v1.0, 12/02/2014
6
5.
SUPERCHARGER MOUNTING PLATE INSTALLATION, CONT’D
H. Start the supplied 8mm bolt in the outside hole
making sure that it does not protrude through the
back and impact the a/c line (2009-2010 5.7L
engines bend the a/c lines slightly as necessary.
Zip tie a piece of supplied 3/4” hose to bracket
to prevent rubbing. See Fig. 5-h).
I. Install a .475” spacer between the supercharger
mounting plate and the power steering pump at
the two remaining power steering pump mounting
holes. Install 8mm x 90mm bolts and washers.
J. Position the supercharger mounting plate assembly in front of the engine and secure it to the
head using the three M8 x 100 mm bolts and one
M8 x 120mm bolt. (See Fig. 5-i).
K. Tighten all of the mounting plate bolts in steps
so that the protruding bolt heads do not hit the
power steering pump pulley.
SUPERCHARGER
MTG PLATE
OEM A/C
LINE
3/4” HOSE
Fig. 5-h
Fig. 5-i
7
P/N: 4CL020-015 v1.0, 12/02/2014
6.
SUPERCHARGER INSTALLATION
A. Install the supplied 3” aluminum idler using the
inner most 3/8-16 hole on the mounting plate
for the idler pulley. Make sure that the snap ring
side is facing forward (away from the mounting
plate). (See Fig. 6-a).
B. Install the supplied power steering pump pulley
on the already installed hub using the supplied
1/4” hardware.
C. Install the supplied accessory drive belt (as
shown in Fig. 6-b).
D. Position the supercharger in front of the mounting
plate assembly in front of the engine and install
and tighten the four 3/8” x 1 ¼” bolts.
E. Install the supplied cog belt around the pulleys
on the mounting plate assembly.
F. Using the supplied M12 x 100mm bolt, install
the supplied 3.5” aluminum idler with the bearing
retaining snap ring pointed towards the front of
the vehicle. The screw should pass through a flat
washer, S/C mounting plate, 1.55” idler spacer,
the idler, thick bearing washer, lock washer and
nut. Install the supplied nut and lock washer on
the end of the screw and tighten the idler so that
the gilmer belt is snug. (See Fig. 6-c).
G. Secure the remote drain hose away from the
belt and hoses using tie-wraps.
2005-2008 5.7L
2009 5.7L
6.1L
Fig. 6-a
Fig. 6-b
Fig. 6-c
P/N: 4CL020-015 v1.0, 12/02/2014
8
7.
A.
B.
C.
D.
E.
AIR INLET INSTALLATION
Locate assembly (4CL112-030) insure that all
parts are present.
Attach the rubber sleeve to the plastic duct with
the hose claps provided.
Attach the air filter to the inlet duct. (See Fig
7-a)
Attach the mounting bracket to the duct with
the fasteners provided. (See Fig 7-b)
Remove the 15 mm headed bolt at the bottom
of the core support. Set the bolt aside to be
reinstalled in a later step (See Fig 7-c)
Fig. 7-a
Fig. 7-b
REMOVE
SCREW
TEMPORARILY
Fig. 7-c
9
P/N: 4CL020-015 v1.0, 12/02/2014
7.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
AIR INLET INSTALLATION, CONT’D
Remove the hood latch cable clip and move to
the side to be reattached to the inlet ductmounting bracket in a later step.
Remove the 3/8” power steering hose from the
drivers side of power steering cooler and from
the reservoir. Set aside; it will not be used.
Locate the 30-inch piece of power steering hose
that is provided. Install the hose clamps from
the factor power steering hose.
Route the new power steering hose down and
behind the core support between the radiator
and the core support. (See Fig 7-d)
Attach the inlet duct to the inlet of the supercharger and secure with the hose clamp previously installed.
Reinstall the 15 mm headed bolt removed in an
earlier step. Attach the hood latch cable to the
bracket supporting the inlet duct. (See Fig 7-e)
Attach the crank case breather hose to the 90º
plastic fitting on the end of the air filter. (See Fig
7-f)
Route the breather hose through the round hole
located in the inner fender to the crank case
breather fitting on the intake manifold.
Check the power steering fluid level and re-fill
as necessary.
Re-install headlight, hardware and connectors.
Fig. 7-d
Fig. 7-e
Fig. 7-f
P/N: 4CL020-015 v1.0, 12/02/2014
10
8. CHARGE AIR COOLER/DISCHARGE ASSEMBLY INSTALLATION
A. Remove the screws securing the coil pack that’s
3rd from the front of the vehicle on the driver side.
Install the supplied discharge tube support bracket
on top of the coil pack, securing it to the engine
using the factory coil pack screws (See Fig. 8-a).
On the passenger side, repeat the same step but
use the 1st coil pack, closest to the front of the
vehicle.
B. Remove the upper alternator bolt & discard. It
will not be reused. Install the supplied bolt into
the upper alternator mount. Be sure to use the
provided washers.
C. Once the supplied bolt is in place, slide on the
supplied .155” spacer & thread on provided nut &
washer by hand. Do not tighten all the way. (See
Fig. 8-b)
D. Using a 15mm socket, remove the screw to the left
of the throttle body, directly above the thermostat
housing. Set screwaside as it will be reused.
E. Locate supplied charge air cooler support. Notice
the bottom of the charge air cooler support is slotted (See Fig. 8-c). Slide the slotted section of the
charge air cooler support in between the .155”
spacer & washer closest to the nut previously
installed on the upper alternator mount. Once the
slotted section of the charge air cooler support is in
place, locate the 15mm screw previously removed
& install through the upper tab of the charge air
cooler support, threading the screw back into its
original location. (See Fig. 8-d)
F. Tighten 15mm screw & upper alternator mount
hardware. Place the charge air cooler on top of
the charge air cooler support.
Discharge Tube
Support Bracket
Fig. 8-a
.155” Spacer
Fig. 8-b
Fig. 8-c
Fig. 8-d
11
P/N: 4CL020-015 v1.0, 12/02/2014
8.
CHARGE AIR COOLER/DISCHARGE ASSEMBLY INSTALLATION, CONT’D
NOTE:For the following procedures, it’s important to
NOT tighten the hose clamps until Step Q.
G. (See “Discharge Tube Identification” below).
Locate discharge tube B & install the supplied
silicone sleeve onto the shorter leg of the tube
with the 45º bends. Place hose clamps hand tight
onto the sleeve but do not tighten all the way.
H. On the shorter leg of discharge tube B, orientate
the hose clamps so they are pushed slightly towards the back. This is in preparation for a later
step. (See Fig. 8-e)
I. Slide a silicone coupler onto the long leg of
discharge tube B, then slide the tube onto the
charge air cooler. Make sure discharge tube B is
resting on the discharge tube support bracket on
the passenger side. This will leave the other end
of the tube near the back of the engine, close to
the firewall.
J. Locate discharge tube C & install the factory IAT
sensor, using the supplied rubber grommet. (See
Fig. 8-f)
K. Install 90 degree silicone elbow onto the throttle
body.
L. Grab discharge tube C & place the tube so that
the section with the two 45º bends are near the
back of the engine, close to the firewall. Slide
discharge tube C into the silicone coupler previously installed onto discharge tube B (See Fig.
8-g). Insert the other end of discharge tube C into
the 90º silicone elbow previously installed on the
throttle body.
M.Locate supplied 1” silicone coupler & cut it so it
can be placed over discharge tube C. Place the
cut coupler over discharge tube C & place it in a
way to trap the drivers side discharge tube support
bracket between the coupler & discharge tube C.
Place supplied hose clamp over the coupler. (See
Fig. 8-h)
Tube B
Fig. 8-e
Tube C
IAT SENSOR
Fig. 8-f
Wiper Arm
Tube B
Fig. 8-g
Tube B
Tube C
Tube A
Fig. 8-h
Discharge Tube Identification
P/N: 4CL020-015 v1.0, 12/02/2014
12
8.
CHARGE AIR COOLER/DISCHARGE ASSEMBLY INSTALLATION, CONT’D
N. Reconnect the IAT Sensor plug to the IAT sensor,
making sure the wire is clear of the cog belt. (See
Fig. 8-i)
O. Locate discharge tube A. Install the supplied
bypass valve & filter onto the welded barb using
the supplied 1” hose. Connect the supplied 5/32”
vacuum hose to the bypass valve & route under
the throttle body, across the driver’s side of the
engine, connecting the other end of the vacuum
hose to the previously installed MAP sensor block.
Use zip ties to secure the vacuum hose to the fuel
injector harness.
P. Place discharge tube A in between the charge air
cooler & supercharger outlet using the supplied
silicone couplers & hose clamps. The end of the
tube with the bends will go onto the supercharger
outlet. Be sure that the bypass valve is pointing
straight down towards the bottom of the vehicle,
making sure that it’s clear of the accessory drive
pulleys & belt.
NOTE:To keep the vacuum hose from rubbing against
the accessory drive belt, it’s suggested to use
zip ties to hold the vacuum hose against the
1” bypass valve hose. (See Fig. 8-j)
Q. Verify that all of the discharge tubes are in place
& proceed to tighten all of the hose clamps. Make
any necessary adjustments to the tubes for proper
fitment. The hose clamps on the silicone coupler
connecting discharge tube B & discharge tube C
installed in a previous step must be tightened using
an 8mm socket, swivel joint & a long extension. The
hose clamps must be pushed towards the firewall
to make clearance for the windshield wiper arms.
Failure to do so will result in the windshield wiper
arms coming into contact with the hose clamps.
R. Locate the engine cover & modify it so the driver
side of the engine cover clears discharge tube
C & the passenger side of the cover clears the
charge air cooler. (See Figs. 8-k, 8-l)
IAT SENSOR PLUG
Fig. 8-i
Fig. 8-j
Fig. 8-k
Fig. 8-l
13
P/N: 4CL020-015 v1.0, 12/02/2014
9.
RESERVOIR AND WATER PUMP ASSEMBLY AND INSTALLATION
A. Attach the surge tank bracket to the surge tank
using 1/4-20 x .5” cap screws. Mount the surge
tank bracket to the slot in the factory coolant reservoir. (See Fig. 9-a)
B. In the area in front of the drivers side front wheel,
position the water reservoir/bracket next to the
frame rail. Orient the assembly for the best clearance, at least 6” from the rear face of the bumper.
(See Fig. 9-b)
C. Mark the mounting bracket location and remove.
Drill two 11/64” holes for the supplied #12 sheet
metal screws.
D. Using thread sealant, install the 1/2” NPT 90° hose
barb fitting into the top and bottom of the supplied
plastic reservoir.
E. Secure the assembly to the frame rail using two
#12 sheet metal screws. (See Fig. 9-c)
F. Trial fit the front bumper cover to verify water
reservoir clearance.
G. Cut off the electrical plug on the water pump
leaving as much wire connected to the pump as
possible. Install the supplied 1/4” eyelet onto the
water pump ground wire (brown wire).
H. Connect the pump inlet to the bottom reservoir fitting with a piece of supplied hose. Point the pump
to discharge forward (and slightly up, to allow air
to escape the pump housing). Secure the hose
with the nylon ratchet clamps on both ends. Drill a
hole in the radiator support and secure the water
pump to it using an adel clamp and #12 sheet
metal screw. Make sure to ground the water pump
under the mounting screw. (See Fig. 9-d)
I. Connect a 90º molded hose to the barbed fitting on
top of the reservoir & secure with a nylon ratchet
clamp (short leg of the hose gets attached to the
reservoir). Locate the supplied 3/4” hose & connect
it to the 90º molded hose using a hose mender &
nylon ratchet clamps. Run the hose up to the area
next to the drivers side valve cover, routing the
hose behind the drivers side headlight. Attach the
3/4” hose to the lower barbed fitting of the surge
tank & secure with a nylon ratchet clamp (cut the
hose to the appropriate length).
J. Drill a 5/8” hole in the rear facing side of the power
distribution box lid approx. 3” from the inner edge.
Insert the supplied grommet into the hole. Install
the supplied fuse holder from the inside of the lid,
pressing one end into the grommet. Connect the
fuse tap and slide connector to the fuel pump fuse
(refer to owners manual for fuel pump fuse). Connect the remaining end of the fuse holder to the
water pump wire using the supplied wire. Route
the wire behind the engine, following the factory
loom. Install the supplied split loom over the wire.
(See Fig. 9-e)
P/N: 4CL020-015 v1.0, 12/02/2014
14
Fig. 9-a
Fig. 9-b
Fig. 9-c
Fig. 9-d
Fig. 9-e
10.
CHARGE AIR COOLER RADIATOR INSTALLATION
A. Attach the supplied brackets to each side of
the CAC radiator as shown in figs. 10-a and
10-b. Remove the 8mm screws from the A/C
condenser & install the CAC radiator to the
condenser. Remove the two small plastic panels
from the front bumper cover as shown in Fig.
10-c.
B. Connect the water pump discharge to the bottom hose barb on the CAC radiator using the
supplied 90º molded hose (and additional 3/4”
hose if needed). See Fig. 10-f (on the next page)
for CAC hose routing.
C. Attach two 90º molded hoses to the CAC core
& secure them with nylon ratchet clamps. Point
the two hoses towards the front of the vehicle.
(See Fig. 10-d)
D. Locate the 3/4” x 150º molded hose & attach
it to the upper hose barb on the CAC radiator.
Connect the other end of the 3/4” x 150º hose
to the 90º molded hose on the water inlet fitting (upper fitting) on the CAC core using the
supplied hose menders & 3/4” hose (cut hose
to the appropriate length). Secure using nylon
ratchet clamps. Run the hose along the top of
the bumper beam. (See Fig. 10-e)
E. Using a hose mender, attach the 3/4” hose to
the remaining 90º molded hose on the CAC
core. Run the 3/4” hose parallel to the previously installed hose, routing the end of the hose
behind the drivers side headlight, up towards
the drivers side valve cover. Attach the other
end of the 3/4” hose to the upper fitting of the
previously installed surge tank & secure with
nylon ratchet clamps. Use zip ties to secure the
two hoses running along the top of the bumper
beam.
F. Remove cap from surge tank and slowly fill system with 25% / 75% coolant/water mix. Check
for leaks.
G. Re-install the front inner and outer fascias and
fender liner in reverse order of removal.
Fig. 10-a
Fig. 10-b
Fig. 10-c
Fig. 10-d
Fig. 10-e
15
P/N: 4CL020-015 v1.0, 12/02/2014
CHARGE AIR COOLER RADIATOR INSTALLATION, CONT’d
10.
  
 




 










  
 
     

       

  
 
  

  
 
 
   


    
  
 
  
 
       




  
 
  

16
P/N: 4CL020-015 v1.0, 12/02/2014
    
CAC HOSE ROUTING
Fig. 10-f
11. FUEL PUMP BOOSTER INSTALLATION
A. Open trunk and remove carpet to expose the
Styrofoam organizer in the spare tire well and
remove the organizer. Using the FPB mounting
plate as a template, mark (2) drill hole locations.
Using a 17/64” drill bit, drill through, at the two
marked locations (see Fig. 11-a).
B. Secure the supplied FPB to the mounting plate
with the provided # 10 hardware screws, washers, and nylock nuts. Then mount the FPB assembly to the two previously drilled 17/64” holes
in the spare tire well using the provided ¼-20
screws, washers, and nylock nuts.
C. Locate the rubber grommet on the driver’s side
of the firewall. Make a small slice in the grommet.
D. Remove the two plastic clips securing the under
dash cover. Set aside the cover to be installed
in a later step. (See Fig. 11-b)
E. Lift up the driver side plastic door sill running
across the door and remove. (See Fig. 11-c) It
will be reinstalled in a later step.
F. Remove the rear seat by lifting up on each side
of the lower section. (The upper section does
not need to be removed)
G. Locate the supplied 1/8” nylon Instrument tubing
and install it into the 1/4” plastic split loom.
H. Route the 1/8” nylon tube assembly along the
door sill to the FPB previously installed in the
trunk. Secure the loom with provided tie wraps.
Locate the 7/64 vacuum hose and cut a 2” piece
and install one end on the 1/8” nylon tube and
the other end to the vacuum port on the FPB.
Secure hose connections with tie wraps. This
will be used for boost reference.
DRILL TWO 17/64”
HOLES
Fig. 11-a
Fig. 11-b
NOTE:When routing tubing, ensure nylon tubing
does not get kinked or potentially pinched
during vehicle operation.
I. Route the other end of the 1/8” nylon tube
assembly loom through the firewall grommet
(Previously cut in step 11-C) and into the engine
bay. Continue routing the tube assembly to the
5/32” tee fitting installed in the bypass valve
line. (Previous step 10-D) Cut another 2” piece
of 7/64” vacuum hose and attach to tee fitting.
Secure with plastic tie wraps.
17
DOOR SILL
Fig. 11-c
P/N: 4CL020-015 v1.0, 12/02/2014
11. FUEL PUMP VOLTAGE BOOSTER INSTALLATION con’t
J. Locate the factory fuel pump wires under the rear
seat driver’s side. Remove the tape from the wires.
Separate the blue with orange or blue with red
depending on model year (See Fig. 11-d).
TO FUEL PUMP
NOTE:Crimp on connectors are provided
but it is recommended that all of the
wire connections be soldered and
insulated.
K. Cut the blue with red/orange trace wire leaving
approximately 4”out of the fuel pump. Attach the
12ga. orange wire provided in your kit to the 12ga.
orange wire from the FPB. Attach the other end to
the fuel pump. This wire will power the fuel pump.
(Refer to wiring diagram Fig. 11-h)
NOTE:Refer to the fuel pump wiring dia-
gram that is provided for further explanation if needed (Fig. 11-h).
L. Attach the 14ga. red wire provided in your kit to
the 14ga red wire from the FPB. Attach the other
end to the blue with red/orange trace wire into the
OEM wire harness. (Refer to wiring diagram Fig.
11-h)
P/N: 4CL020-015 v1.0, 12/02/2014
18
TO WIRING HARNESS
Fig. 11-d
M. Reinstall the rear seat, door sill, and under dash
cover at this time.
N. On the FPB box, locate the red 12 ga. wire with
fuse holder. Cut off the fuse holder and discard.
Locate the 12 ga. red wire provided and connect where fuse holder was cut off. Locate the
provided black 12ga. wire and connect to the
black wire on the FPB.
O. Route the red power wire and black ground wire
toward the fuse box next to the battery. Trim the
wires to proper lengths to attach to factory ground
lug and factory power distribution box. Locate
the provided fuse holder and cut the center of
the wire loop. Attach one end to the red 12 ga.
power wire from FPB. Use the supplied ring
terminals crimp, solder, and attach to factory
lugs. (See Figs. 11-e, 11-f, 11-g for close up
view.) Install the supplied 40amp fuse into fuse
holder after all connections are complete.
P. Reinstall the trunk organizer and carpet at this
time.
Fig. 11-e
POWER WIRE
TERMINAL
Fig. 11-f
GROUND LUG
Fig. 11-g
19
P/N: 4CL020-015 v1.0, 12/02/2014
WIRING DIAGRAM
Fig. 11-h
P/N: 4CL020-015 v1.0, 12/02/2014
20
12.
REFLASH COMPUTER
IMPORTANT!
To ensure trouble-free programming of your vehicle's computer:
• Make sure the vehicle's battery is sufficiently charged.
• Turn off all accessories and close doors to prevent unnecessary drain on the battery.
• Do not attempt to program your vehicle while a battery charger is connected.
• Improper battery voltage will result in failure of the programming process.
• Do not disconnect the cable or turn off the ignition during programming.
A.
B.
C.
D.
E.
F.
G.
H.
Reconnect the battery.
Locate the vehicles OBD2 connector located
below the dash on the driver’s side of the
vehicle.
Attach the OBD2 connector from the Flash
tool that is provided in the kit to the vehicle’s
OBD2 port. Make sure this connector is seated all the way in the vehicle’s OBD2 port. You
do not want this connector coming out during
programming or damage may occur to the
vehicle’s ECM.
The Reflash tool should power up and display
three parameters. (See Fig. 13-b)
1. Tune Vehicle
2. Scan Tool
3. Settings
Select “Tune Vehicle” by pressing the icon.
Read the disclaimer entirely, then select
agree and press enter.
At this point follow the instructions on the
screen displayed on the reflash tool. If you
have any questions, either refer to the manual that is provided with the reflash tool or contact our service department for further assistance.
Turn the ignition on (do not start the vehicle).
Set the parking brake and press the enter
button to continue.
NOTE:
I.
J.
FLASH TOOL
OBD2 CABLE
Fig. 13-a (inTune Programmer)
Do not disturb the cable, or turn the ignition off during this time. If the programming is disrupted, the computer will not start or run your vehicle!
SELECT TUNE will be displayed at the top of
the screen. Select the appropriate tune for
your vehicle. You will have a choice of two to
choose from:
1. Vortech (used for installing kit)
2. Original Backup
Continue to follow the screen and when finished, unplug the reflash tool from the vehicle’s OBD2 port.
Fig. 13-b (inTune Touchscreen Display)
21
P/N: 4CL020-015 v1.0, 12/02/2014
13. FINAL ASSEMBLY AND CHECKING
NOTE: This supercharger has been factory
pre-filled with special synthetic lubricant. Oil does not need to be added to a
brand new unit. However the following
fluid level check should be performed.
A. Remove the factory installed flat head brass shipping
plug (not the dipstick) from the top of the supercharger
case.
B. Replace the sealed shipping plug with the supplied
“vented” plug. Do not operate the supercharger
without it.
C. Ensure that the .06” copper sealing washer is located
on the dipstick base.
D. Thread the clean dipstick into the supercharger until
it seats.
E. Once the dipstick has seated, remove the dipstick from
the unit. Fluid should register in the crosshatched
area on the dipstick.
F. DO NOT OVERFILL!! Drain excess fluid from the
unit if it is above the maximum level on the dipstick.
Install and tighten the dipstick in the gearcase.
G. If your vehicle has gone over 20,000 miles since its
last spark plug change, it is a good idea to change
the spark plugs now, before test-driving.
H. Make sure that the vehicle is filled with 91 octane or
higher fuel before commencing test drive.
I. With key on, make sure charge air cooler water pump
is operating and that water is flowing through the
surge tank. Fill as necessary. If water is not flowing,
remove the hose from the bottom of the surge tank
and lower until water flows out of hose. This should
prime the pump. Reconnect hose, verify water flow
and top off surge tank. Do not run the water pump
for extended periods (30 seconds or more) without
water flow.
J. Check all fittings, nuts, bolt and clamps for tightness.
K. At this point it is OK to start the vehicle.
Warning: Do not attempt to operate the vehicle until ALL components are installed and ALL operations are
completed including final check. Failure to do so may cause PREMATURE FAILURE OF MAJOR COMPONENTS.
L. With engine running, check power steering hose connections for leakage. Let engine run for two minutes.
Turn steering wheel in both directions.
P/N: 4CL020-015 v1.0, 12/02/2014
22
Fig. 13-a
13.
FINAL ASSEMBLY AND CHECKING con’t
Verify:
• Smooth power assist
• Noiseless operation
• Proper fluid level
• No system leaks
• No bubbles, foam or discoloration in fluid
M.Verify that the gilmer belt is running smoothly. If wear is
detected on the side of the belt, it is probably too tight.
If it is vibrating excessively, tighten until there is minimal
movement.
N. Turn off vehicle and recheck all fluid levels and verify
that no hoses, wires, etc. are near exhaust headers or
moving parts and that there is no fluid leakage.
O. Re-install the splash pan.
P. Test drive vehicle by gradually working up to full throttle
and paying close attention to any abnormal sounds or
engine detonation.
Q. Install the engine cover by trimming the driver side to
clear the supercharger kit.
R. Read the STREET SUPERCHARGER SYSTEM
OWNER’S MANUALAND RETURN THE WARRANTY
REGISTRATION FORM within thirty (30) days of purchasing your supercharger system to qualify for the 3
year limited warranty.
Warning: Never operate your engine at full throttle when the engine is cold. Always alloW
plenty of time for the oil to reach full
operating temperature before running above 2,500 RPM. Full supercharger
operating temperature is generally achieved only after the engine water
temperature has been at the normal indicated operating range for two or three minutes.
V3 supercharger long term maintenance and care:
• CAUTION: Use of any fluid other than the Vortech
supplied synthetic lubricating fluid will void the warranty
and may cause component failure.
Replacement Vortech SL lubricating fluid part numbers:
009035: Package of three 4 oz. bottles
• Check the fluid level using the dipstick at least every
2,500 miles.
• Initial supercharger fluid change must be performed
at 2,500 miles. The supercharger fluid must then be
changed at least every 7,500 miles.
1. Drain the fluid, re-fill the unit only with 4 oz. of Vortech
supplied synthetic lubricating fluid.
2. Confirm proper oil level using the dipstick. DO NOT
OVERFILL!!
23
P/N: 4CL020-015 v1.0, 12/02/2014
®
ENGINEERING, INC
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 7:00 AM - 3:30 PM PST
P/N: 4CL020-015 v1.0, 12/02/2014
24

5.7L Hemi Cars - Vortech Superchargers

Transcription

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